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SYNOPSIS
New distribution functions are derived to describe the size distribution of grinding elements in ball mills. The
formulations are based on the assumption that abrasive as well as impactive interactions occur during ball milling-an
assumption that is supported by a large body of experimental evidence. It is shown that the functions can be used
in the estimation of the magnitudes of abrasive and impactive components in the total rate of ball wear.
The relative magnitudes of the wear components provide a basis for optimization of the chemical and metallurgical
properties of the balls in a given milling situation. However, it is contended that these quantities are also useful
indicators of the relative intensities of the abrasive and impactive interactions that are operative in the size reduction of mineral particles within ball mills. These quantities can be determined for any industrial ball mill, and their
magnitudes provide practical guidelines for mill operation.
The theory is used in an analysis of samples of ball charges from two industrial ball mills, and it is also applied
to all the data on ball-size distributions found in the literature. The qualitative correlation between the calculated
values of the wear components and the reported operating conditions is good for a variety of industrial ball mills,
in conformity with the hypothesis that the relative magnitudes of the wear components are related to the milling
.
conditions.
SAMEVATTING
Daar word nuwe verdelingsfunksies
afgelei om die grootteverdeling
van maalelemente
in balmeule te beskryf.
Die formulerings
word gegrond op die aanname dat daar sowel skuur- as slagwisselwerking
tydens balmaling
getuienis gestaaf word. Daar word getoon
plaasvind-'n
aanname wat deur 'n groot hoeveelheid eksperimentele
dat die funksies gebruik kan word om die grootte van die skuur- en slagkomponente in die totale tempo van balslytasie
te raam.
Die relatiewe grootte van die slytkomponente
verskaf 'n grondslag vir die optimering van die chemiese en
metallurgiese eienskappe van die balle in n gegewe maalsituasie. Daar word egter aangevoer dat hierdie groothede
ook nuttige aanwysers is van die relatiewe intensiteit van die skuur- en slagwisselwerking
wat plaasvind tydens
die verkleining van mineraalpartikels
in balmeule. Hierdie groothede kan vir enige industriele balmeul bepaal word
en verskaf praktiese riglyne vir meulbedryf.
Die teorie word gebruik om monsters van balladings wat uit twee industriele balmeule verkry is, te ontleed en
word toegepas op al die data oor balgrootteverdelings
wat in die literatuur gevind is. Die kwalitatiewe korrelasie
tussen die berekende waardes van die slytkomponente
en die gerapporteerde
bedryfstoestande
is goed vir 'n
verskeidenheid industriele balmeule in ooreenstemming
met die hipotese dat die relatiewe groothede van die slytkomponente met die maaltoestande
verband hou.
Introduction
Ball milling has been employed for more than a hundred years in the fine grinding of ores, coal, cement, and
other materials. The world's consumption of grinding
balls used in this way is about 500 kt a year, and the consumption of balls per ton of material milled varies widely. Ball consumption constitutes a significant proportion
of the costs of fine grinding, rising markedly for hard
and abrasive ores. In attempts to reduce ball consumption and the high cost of fine grinding, many studies have
been directed to the analysis of factors causing ball wear.
These studies have almost invariably attributed all the
wear to one of the two wear mechanisms that operate in
ball milling: abrasive wear and imp active wear.
That abrasion plays a large part in all fine-grinding
operations has long been known and acknowledged. Over
forty years ago, Prentice' reported tests aimed at providing evidence that all the wear of grinding balls is caused
by abrasion. Much additional evidence has since been
. SpecialistScientist,Council for MineralTechnology(Mintek),
Private Bag X3015, Randburg, 2125 Transvaal.
APRIL 1986
113
dm
dT
k' Xq,
(1)
(2)
APRIL 1986
(3)
JOURNAL
,,(X)dX
n(X)
Xo
(4)
xmax
(X)dX
Xo
"
and
j XJ"
m(X)
(X)dX
Xo
-
(5)
xmax
~
XJ,,(X)dX
Xo
N, =
j ,,(X)dX.
(6)
xi
If ~ is constant, its derivative with respect to the
amount of material milled, T, is zero, Le.
OF THE SOUTH
AFRICAN
INSTITUTE
Xj
dN
d
- v (X)dX
'
dT
dT Xi
V(X)
dX
'
dT
dX,
V(X) = O.
dT
(7)
dX
veX)
is constant.
(8)
dT
nc(X,q)
X~;~6
(X)
~.
(9)
dX/dT
dm
= k' Xq,
dT
(1)
dX
dT
= kXq-2,
(10)
OF THE SOUTH
(11)
XoOJ6
(16)
XoO,J6
where Xo = 1,0 inch and Xmax = 4,0 inches. For purposes of comparison, the respective number distribution
functions nA(X) and n!(X) for purely abrasive and purely impactive wear (Table I), with the same values for X
and Xmax' are also depicted in Fig. 1. The functio~
nc(X,q) for combined wear gives the best description of
the measured ball-size distribution. Equations (14) and
(16) show that q, as determined from the numberdistribution function, is
q(nc) = 3 - 0,36 = 2,64.
A similar analysis, in which the mass distribution function for combined wear mc(X,q) and the measured mass
distribution were used, yielded
q(mc) = 2,28.
Despite a discrepancy of about 15 per cent between the
two estimates of q, the results suggest fairly strongly that
the balls in the mill were subjected to a significant impactive component.
It is clear that exponent q is a number, and that the
determination of its value provides only a qualitative indication of the relative intensities of abrasive and impactive wear in a given mill.
Bond's empirical relation, which was shown in equation (1), can be replaced by a more detailed analysis that
leads to the determination of the magnitudes of the two
components in the rate of ball wear. The rates of abrasive
and impactive wear are superposed in the following manner: during abrasion the rate of ball wear is proportional
to the surface area of a ball!, Le.
dm
ex m2/J;
- dT
during impact the rate of ball wear is proportional to the
mass of a ballJ, Le.
- -dm
ex
m.
dT
AFRICAN
INSTITUTE
APRIL 1986
115
TABLE I
EXPRESSIONS TO CHARACIERIZE A STABILIZED BALL-SIZE DISTRIBUTION UNDER COMBINED WEAR AND UNDER THE HYPOTHETICAL
CONDITIONSOF PURELY ABRASIVE AND PURELY IMPACTIVE WEAR ACCORDING TO THE BOND FORMULATION OF THE RATE OF BALL WEAR
Formula
-~;OCxq.............
Number
density function
vc(X,q)
Number
mill
of balls in the
Nc(q)
(1)
n'
kXq-2
. . ..
X:-q)
n' pJt(X;;;.q -
dm
dT
vA(X) = ~
k
(12)
NA = k n' (Xmax-
n'pJt
4
MA - 24j{(Xmax-X.)
Number distribution
function of balls
smaller than size X
nc(X,q) =
q
x~xq - X;
. . . . . . (14)t
X-X.
nA(X) =
Xmax- X.
Mass distribution
function of balls
smaller than size X
x6-q - X:-q
mc(X,q) =
q
X.:..q- X:
. . . . . . (15)t
mA(X) =
x3-q
- X.q-3
oc m
n'
N, = T(lnXmax-lnX.)
X.)
Mc(q) =
. , . . (13)
dm
dT
v,(X) = n'
kX
6k(6 - q)
(limiting form as q ~ 3)
oc m%
(11)
"""""
n'(X,;;;;.q - x;-q)
k(3 - q)
Quantity
X4 - X.4
- X.
X':'"
M, -
pit
n'rsi(
3
( Xmax
n.(X)
InX-lnX.
= InXmax-lnX.
m,(X) =
- X.3 )
X3 - X;
X~ - X;
Xm"
0
n,(X)
m..
nA(X)
ndX,q)
~4.0in
~ Experimental data'
~ Number fraction for purely impacUve wear
Number fraction
~ Number fraction
q ~ 2,64
when
,./'{/!
...../" 1/
0,8
0,6
'<'
,/
..
"
B",
~~
1:
" .,
'.
WI(X)
ap7rX3
(18)
6
and
WA(X)
1
1
../~' /f
(3(! p7rXY3
6
(19)
~"/~c/~/ /
04
'
]
U
"
/;:;.
E ,=
'~
.i
.l/
...... 11
./ /
..../ 1/
~ 1.0in
x"
1,0
../
/ /
//
i~/
; 1
0,2
//
i/
//
I
'I
1
dX
Ball size X. in
d!
(20)
where
A=
(3
a(p7r/6)
113
(21)
dT
116
Dim
+ flm2i\
APRIL 1986
,..,..,
(17)
JOURNAL
The number density function, obtained by the substitution of equation (20) into equation (9), is
OF THE SOUTH
AFRICAN
INSTITUTE
TABLE 11
EXPRESSIONSTO CHARACfERIZE A STABILIZED BALL-SIZEDISTRIBUTION UNDER CONDITIONS OF COMBINED WEAR
Quantity
General
Formula
dm
- - dT
Number
density function
vc(X,I.) =
Number
Nc(l.) = 3n'
a- In
distribution
Mass distribution
(abrasive
and impactive)
wear'
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
( Xo ++AA)
n'pJ[
2(\
Xmax
-X 0
[ ...L(x>
3
max
In (X + A) -In
9~
LI.(X2
2
max
_X2)+1.2(X
0
max
( Xmax+I.
+ A )J
-X)-I.>ln
0
.. . . . ..
mc(X,I.)=
function
(Xo + A)
(X> - X;) -
...L(X3max -X3)0
(24)
Xo
(25)
nc(X,I.) =
In(Xmax+I.)-ln(Xo+l.)
function
(17)
(22)
'Based
for combined
(\(ln~l.)
M c (A) =
Number
2;
= (\m+~m;>
expression
I.(X2 - Xo2)
+ 1.2(X
LI.(X2max _X2)+1.2(X
0
- Xo) - 1.>ln
max
( :.:~ )
( Xmax+l.
)
+A
-X)-I.>ln
0
. . . . . . . . ..
(26)
Xo
wear rates
3n '
.
(22)
a(X + A)
[his function is expressed as a function of A, because the
latter has important physical significance within the present context, which will be discussed further.
Expressions equivalent to those listed in Table I, derived by the subi'titution of equation (22) into equations (2)
to (5), are shown in Table 11. In addition to these
equations-(23) to (26)-expressions can be derived for
the cumulative number and cumulative mass of balls
smaller or larger than a given size, the number and mass
of balls in a size interval, the mean ball diameter, the surface area of the ball charge, and so on.
The parameter A in the expressions above is proportional to {31a so that, if {3tends to zero, then Aalso tends
to zero. The expressions in Table 11 then reduce to the
corresponding expressions that are applicable under
hypothetical conditions of purely imp active wear (Table
I). On the other hand, if {3is finite and a tends to zero,
then A tends to infinity. The expressions in Table 11then
reduce to the corresponding expressions that are valid
under hypothetical conditions of purely abrasive wear
(Table I).
vc(X, A) =
Xmax
WA(charge) =
WA(X)V(X,A)dX
Xo
+ A2ln
Xmax + A
Xo
(27)
+ AJ
Similarly,
W,(charge) = Yz n'p1T
JOURNAL
OF THE SOUTH
1/3(X~ax
AFRICAN
- X~)
INSTITUTE
Y2A(X~ax - X~)
+ A2(Xmax- Xo)
AJlnXmaX+ A
(28)
1986
117
Xo + A J
APRIL
Hence, the ratio 0 f the rates of abrasive to impactive wear on the ball charge is
V2A(X~ax - X~)
R Al charge)
- A2(Xmax- XJ
- X~)
V2A(X~ax - X~)
+ A2(Xmax- Xo)
Equation (29) shows that the ratio RAI(charge) is independent of lX, (3, and the rate of ball consumption. It
is a function only of A, Xo, and Xmax' The quantity A
can therefore be used to express quantitatively the relative
magnitudes of the rates of abrasive and impactive wear
that are operative on the whole ball charge. It is contended that not only are these quantities related to ball wear,
but they are also important indicators of the mechanisms
of size reduction of mineral particles in a given milling
situation. Hence, their calculated magnitudes should correlate with the milling conditions, e.g. mill diameter, mill
speed, liner configuration, pulp density, ball size.
Furthermore, A can also be related to the exponent q
in the Bond formulation of ball wear. The relationship
is found by the use of equations (12) and (13) in Table
I in conjunction with equations (23) and (24) in Table
11, to yield equation (30):
- X~)
V2A(X~ax - X~)
1n(Xmax + A)
+ A(Xmax - Xo)
APRIL 1986
JOURNAL
.(29)
AJln Xmax + A
Xo + A
AJln Xmax + A
Xo + A
1n(Xo + A)
Xmax + A
Xo + A
l/3(X~ax
l/3(X~ax
+ AJln
(3 (6 -
q) (X~:xq -
x,~-q)
q) (X~:xq
xt'1)
(30)
OF THE SOUTH
AFRICAN
INSTITUTE
f
'f
(a) -=Distribution
function
nc(X,"A) with "A=8,1 inches
@)
0,8
= Prentice's experimental
datal
R
t::
'"'-
(c)-
~
';:: i!:! 0,6
;;j';;;
....
co
~ ,~
';::
.!So.~
0,4
='
S
u='
0,2
R
'"'-
(b)
-=
Distribution
function
0,8
mc(X,"A)
(d)-=Distribution
function mc(X,q)
with q = 2,20
<!) = Prentice's experimental data I
datal
EO
d"
,g
0,6
gf
e'~
... 0:1
0,4
t;i
"3
S
0,2
;;j
i!:!
<Z::';;;
~
,~
0.
u='
Fig. 2-Comparison
XO,S4
=
Ball size X, in
of measured and calculated size distribution of balls in the charge of the ball mill at Blyvooruitsig Gold Mine
Ball size X, in
3,84
- 0,6,84
0,6O,S4
and
X3,so
- 0 63,so
mc(X,q) =
'.
33,so 0,63,so
-
This value of ;\ is in good agreement with those determined previously, which confirms the internal consistency
of the theory.
The mean of all the values of ;\ obtained so far gives
~Blyvooruitsig= 208 mm.
APRIL 1986
119
10-5 kg t-I,
and
Wj(m) = am ::::::1,1 x 10-5 kg cl.
These values, for balls of average mass, indicate that
abrasive interactions were predominant in the given mill.
That this was characteristic of the whole charge in the
mill can be confirmed by calculation of the rates of
abrasive wear and impactive wear on the whole ball
charge, viz WA(charge) and W1(charge). Quick estimates, which can be confirmed by detailed calculations
based on equations (27) and (28), indicate that, since Nm
is the total mass of the charge (13 309 kg), the charge
experienced an impactive wear rate of
Wj(charge
aNm
::::::0,26
kg t-I.
minus
The ratio RAI(charge) of the rates of abrasive to impactive wear on the ball charge was therefore
RAI(charge)
:::::: 3,5.
APRIL 1986
,-
1,0
,/
"
component
34070
= Experimental
= nI(X); purely
data
impactive wear
= nA(X); purely abrasive wear
= nc(X, A); combined wear
'I
= Experimental
data
:'/
,/:/
:/
:'/
:/
:'/
:'I
0,8
1/
:/
:'/
:/
1/
:/
~/
:'I
:/
:'I
:'/
1// nA(X)
r4
.'/
:'/
:/
1/
:/
:'!
1/
:/
'"~
ci'
0
0,6
'~ ~
.:::
1;\
t't;;
oD bI)
EL5
a ~0. 04,
<1)
,:;
C;j
"'5
8
;::I
1/
0,2
/1
It
0
0
20
40
60
80
100
Ball size X, mm
Fig. 3-Comparison
40
60
Ball size X, mm
20
APRIL 1986
121
TABLE III
MILLING CONDITIONS
Grinding balls
Mill
Diameter
ft
Mine
Length
ft
Speed
070
of
critical
Volume
of
charge
%
Top
size
mm
Miami CopperJ
(Hardinge conical
mill)
82
20
50,8
Marikana
Western Platinum
Limited
80
45
Marievale'
83
Lakeshorel4
no. 7 ball mill
Libanon
IN SOME INDUSTRIAL
0,0033
99,7
10,17
0,203
0,26
74
67,5
0,66
0,91
52
1,28
1,72
36
149
1,42
1,88
34,7
2,17
127
1,67
2,18
30,5
15
2,17
207
2,73
3,65
21,5
2,13
483
4,75
6,4
13,5
25
2,78
47
120
25
2,46
85
45
108
25
2,31
138
10
79
48
108
30
2,30
6Yz
12
80
50
76
Blyvoortuitsig'
6Y,
12
70
25
76
Sub Nigel'
6Yz
68
33
100
,
I
Sub
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
Nigel
i!)
Theoretical
relationship
at values
of Xm.,/
Xo:
-~2
~
~
-~
---
5
ID
00
I :
:\
:\
: \\
I
\1\:\\
~
>
11\
~
13
~
\\ \\\\
e~
\ \\
\ \\
E
0
to
Blyvo~r.
~\
\\
\.
\\ \\ \'.
'2
a.
~E
\ ~..Lakeshore2
\\
Hollinger1i>
~,
\ ...~ $
..
"
,\\o<e1
" \
):
~
0'< "
,..0;;:'
- - - \-', ""'..."
~'..;-~v~' -.~.. - - - - - ..~ - - -;;
'<-'...@'.,i.,o
~
:~;;.~..
"
\.,~"e
""
-"'
Fig.
2,0
2.2
4-Values
2,4
2,8
2.6
of AIXmlX as a function of q
distributions
122
""
APRIL 1986
~~~,g
.~ ~
~~~~~:~:~':;~~:.~~
"""
0
1i
'"
in a number
for the
of mills
0
u
~
3.0
bail-size
Ratio of Impactive
wear
abrasive
% of
0 impactAIXmax ive wear total wear
Small
60
15
BALL MILLS
Calculated parameters
2,97
7.5
Reject
size
mm
COMPONENT
Hollinger
~
):
OF THE IMPACTIVE
0,0047
TABLE
III (cont.)
TABLE A-II
BALL-SIZE DISTRIBUTION AT THE BLYVOORUITSIG GOLD MINE,
18TH OCTOBER, 1942 (AFTER PRENTICE1)
Grading of
charge
inch
<3
<2V,
<2
<1Y2
<I
High speed with lifter bars in linings; hence cataracting conditions and strong impactive component
>2Y2
>2
>1Y2
>1
Total
High speed and large grinding balls enhance impactive component, whereas smooth lining limits cataracting; hence impactive and abrasive components
almost equal
Mass
070
Average
Total mass mass per ball Number of
Ib
Ib
balls
53,34
2225
17,05
5,90
1,46
15 650
6528
5002
1732
428
3 114
1,774
0,890
0,333
0,099
5026
3680
5623
5198
4316
100,00
29 340
1,231-
23 843
-Average
TABLE A-III
SIZE DISTRIBUTION IN A SAMPLE OF BALLSFROMTHE CHARGE OF
NO. 2 BALL MILL AT LIBANON GOLD MINE
Size range
mm
20
30
40
50
60
70
80
90
100
<4
<3Y2
<3
<2Y2
<2
<IV,
Total
>3Y2
>3
>2Y2
>2
>1Y2
>1
Number of
balls
45,3
18,7
17,6
7,7
8,6
2,1
2282
1423
2240
1792
4268
2935
100,0
14940
Prentice
theoryl
Davis
theory'
2185
2185
2 185
2 185
2 185
2 185
I 685
1947
2304
2820
3636
5124
13110
17 516
31
132
185
249
190
183
170
178
64
1382
TABLE A-IV
SIZE DISTRIBUTION IN A 344 kg SAMPLE OF BALLS FROM THE
CHARGE IN THE NO. 3A-STREAM BALL MILL AT THE MARIKANA
MINE OF WESTERN PLATINUM LIMITED
Ball size
mm
>30
>35
>40
>45
>50
>55
TABLE A-I
BALL-SIZE DISTRIBUTION AT MARIEVALE (AFTER WHITE')
Mass
30
40
50
60
70
80
90
100
105
Total
Addendum
Ball-size distribution data that were analysed by the
theory of combined wear are given in Tables A-I to
A-IV.
Ball size
inch
to
to
to
to
to
to
to
to
to
Number of
balls
<30
<35
<40
<45
<50
<55
<60
Total
Number of
balls
204
156
189
179
141
101
100
1070
Acknowledgements
This paper is published by permisison of the Council
for Mineral Technology (Mintek).
Thanks are due to Dr P.T. Wedephol for proposing
this investigation and to Dr M.A. Ford for suggesting fur-
APRIL 1986
123
384-388.
6. BOND, F.C. Wear and size distribution
of grinding balls. Trans.
AIME,
vol. 153. 1943. pp. 373-384.
7. WHITE, H.A. Vote of thanks to the Prentice paper. J. Chem.
Metall. Min. Soc. S. Afr., Jan. 1943. pp. 116-122.
8. BOND, F.C. Written contribution
to discussion of the Prentice
paper. J. Chem. Metall. Soc. S. Afr., Jan-Feb.
1943. pp. 131-133.
9. HUKKI, R.T. Correlation
between principal parameters
affecting
mechanical ball wear. Trans. AIME, vol. 199. 1954. pp. 642-644.
10. TAGGART, A.F. Handbook
of mineral dressing. New York, John
Wiley & Sons, 1954. pp. 5-27.
11. VERMEULEN, loA., and How AT, D.D., Quantitative
assessment of
abrasive and impactive wear rates from ball-size distributions
in
rotary mills. Randburg,
Council for Mineral Technology,
Report
M201. May 1985.
12. BERNUTAT, P. Wear of grinding media and liner plates. ZementKalk Gips, no. 9. 1964. pp. 397-400.
13. ADAMSON, R.J. Gold metallurgy in South Africa. Johannesburg,
Chamber of Mines of South Africa, 1972. p. 45.
14. CROCKER, B.S. Written contribution
to the paper by T.K. Prentice. J. Chem. Metall. Min. Soc. S. Afr., Feb. 1944. pp. 133-136.
15. LONGMORE, E.lo, et al. Comparison
of Iow imd high discharge for
ball mills. Trans. Instn Min. Metall., vol. 46. 1937. pp. 562-583.
16. TAGGART, A.F. Op cit., p. 5-65.
17. FLOoK, W. General Mining Union Corporation
Ltd. Private communication,
1984.
18. NORMAN, T.E., and LOEB, CM. Wear tests on grinding balls.
Trans. AIME,
vol. 1983. 1949. pp. 330-360.
19. NORQUIST, D.E., and MOELLER, J.E. Relative wear rates of
various diameter grinding balls in production
mills. Trans. AIME,
vol. 187. 1950. pp. 712-714.
20. AuSTIN, loG., and KUMPEL, R.R. Ball wear and ball size distributions in tumbling ball mills. Power Technology,
vol. 41. 1985. pp.
279-286.
Ion-Ex '87
Papers are invited for Ion-Ex '87, an International
Conference and Industrial Exhibition on the industrial,
analytical,
and preparative
applications
of ion
chromatography and ion-exchange processes, which is to
be held on 13th to 16th April, 1987, in Wrexham, Wales.
The Conference is supported by the Royal Society of
Chemistry Analytical Division (North West Region) and
the Society of Chemical Industry, Solvent Extraction and
Ion Exchange Group, together with major organizations
involved in the field.
The proposed scope of the meeting is to include the
following general areas, and each will be reviewed by a
recognized authority.
.
.
biochemical, preparative, and assay techniques. Exchange resins and instrumentation (Review Dr F.C.
Smith, Millipore SA, France)
Polyelectrolyte fractionation processes
Industrial water-purification procedures, including
effluent treatment (Review: Dr J .R. Millar)
IPMI conference
Dr M.L El Guindy has been appointed General Chairman of IPMI's 10th International Precious Metals Conference and Exhibition. The meeting is to be held at Lake
Tahoe, Nevada, from 9th to 12th June, 1986.
The theme of the Conference will be 'Interactive
Precious-Metal Technology-Producer
to User'. Sixtynine presentations will be given by international experts
on subjects such as precious metals in space-related industries, precious metals from natural resources, and
high- technology applications.
The Conference will mark the official celebration of
the tenth anniversary of the International Precious Metals
124
APRIL 1986
Institute. A special limited-edition one-ounce commemora' .ve silver medallion will be struck for the occasion. ~md a 52-page anniversary book highlighting the
history, accomplishments, and awards of IPMI will be
prepared.
Advance registration forms or additional information
can be obtained from
IPMI
Government Building
ABE Airport
Allentown, PA 18103,
U.S.A. Telephone: (215) 266-1570.
r~